Treating waste streams with organic content

ABSTRACT

Embodiments of systems, devices, and methods for treating, remediating, or abating carbon-containing wastes generate at least one of clean water; non-toxic, non-hazardous ash; or power. Some embodiments are modular, permitting rapid deployment, flexible configuration, and easy transportation. Embodiments of the systems treat carbon-containing aqueous waste, carbon containing waste, or a combination thereof. The systems, devices, and methods are particularly suited to treating hydrocarbon containing waste generated in oil and natural gas drilling and hydrofracturing.

BACKGROUND

1. Technical Field

This disclosure relates to devices, systems, and processes suitable fortreating waste streams containing organic compounds, and moreparticularly, for treating waste streams containing hydrocarbons.

2. Description of the Related Art

Disposing of hydrocarbon-containing waste streams often poses costlyproblems for various industries. For example, disposing of wastegenerated from drilling oil wells is not only increasingly expensive,suitable disposal sites are also increasingly scarce. Hydraulicfracturing, hydrofracturing, or fracking, a method used in oil and gasdrilling, uses high pressure water in combination with sand andchemicals to break apart underground rock formations, thereby releasingoil and/or gas trapped therein. Hydraulic fracturing typically generateslarge volumes of waste requiring disposal or remediation. In someinstances, hydraulic fracturing generates thousands or even millions ofliters of waste per day per well. The cost of environmentallyresponsible disposal of large amounts of waste makes oil or gasproduction unfeasible in some locations.

SUMMARY

Embodiments of systems, devices, and methods for treating, remediating,or abating carbon-containing wastes generate at least one of cleanwater; non-toxic, non-hazardous ash; or power. Some embodiments aremodular, permitting rapid deployment, flexible configuration, and easytransportation. Embodiments of the systems treat aqueous waste,carbon-containing waste, or a combination thereof. The systems, devices,and methods are particularly suited to treating hydrocarbon-containingwaste generated in oil and natural gas drilling, for example, inhydrofracturing.

Some embodiments provide a method for remediating a carbon-containingaqueous waste, the method comprising: electrocoagulating thecarbon-containing aqueous waste to provide floc and a liquid phase;removing the floc from the liquid phase; physically separating theliquid phase into a light fraction and a heavy fraction; converting atleast a portion of the light fraction into water with a selected purity;mixing at least one of the floc and the heavy fraction with acarbon-based material to provide a mixture; gasifying the mixture toprovide ash and syngas.

Some embodiments provide a method for remediating a carbon-containingwaste, the method comprising: contacting carbon-containing waste with acarbon-based material to provide a mixture; gasifying the mixture intoash and syngas; and generating power from the syngas.

Some embodiments provide a method for remediating a carbon-containingaqueous waste, the method comprising: electrocoagulating thecarbon-containing aqueous waste to provide floc and a liquid phase;removing the floc from the liquid phase; physically separating theliquid phase into a light fraction and a heavy fraction; and convertingat least a portion of the light fraction into remediated water.

In some embodiments, electrocoagulating the carbon-containing aqueouswaste comprises electrocoagulating wastewater from oil or natural gasdrilling, or from hydrofracturing. In some embodiments,electrocoagulating the carbon-containing aqueous waste comprisesadjusting a pH of the carbon-containing aqueous waste.

In some embodiments, removing the floc from the liquid phase comprisesallowing at least a portion of the floc to at least one of precipitatetowards a bottom of or float towards a top of the liquid phase. In someembodiments, removing the floc from the liquid phase comprises adding aflocculating agent. In some embodiments, removing the floc from theliquid phase comprises at least one of draining or skimming the flocfrom the liquid phase. In some embodiments, removing the floc from theliquid phase comprises dissolved air flotation of the floc.

In some embodiments, physically separating the liquid phase comprisesphysically separating the liquid phase by at least one of weight ordensity. In some embodiments, physically separating the liquid phasecomprises physically separating the liquid phase into a first lightfraction and a first heavy fraction, and further comprises physicallyseparating the first heavy fraction into a second light fraction and asecond heavy fraction.

In some embodiments, converting at least a portion of the light fractioncomprises at least one of filtration, activated carbon filtration,charcoal filtration, sand filtration, diatomaceous earth filtration,membrane filtration, microfiltration, ultrafiltration, nanofiltration,reverse osmosis, distillation, or vapor compression distillation, UVirradiation, gamma irradiation, sterilization, chlorination, ozonation,electrodeionization, or ion exchange. In some embodiments, converting atleast a portion of the light fraction comprises microfiltration andreverse osmosis. In some embodiments, converting at least a portion ofthe light fraction comprises vapor compression distillation. In someembodiments, converting at least a portion of the light fractioncomprises generating a concentrate or residue comprising contaminantsand/or impurities.

Some embodiments further comprise mixing the concentrate or residue withthe carbon-based material to provide the mixture.

In some embodiments, mixing at least one of the floc and the heavyfraction with a carbon-based material to provide a mixture comprisesheating the mixture. In some embodiments, mixing at least one of thefloc and the heavy fraction with a carbon-based material to provide amixture comprises mixing a carbon-containing waste with the carbon-basedmaterial. In some embodiments, mixing at least one of the floc and theheavy fraction with a carbon-based material comprises mixing at leastone of the floc and the heavy fraction with at least one of kenaf, kenafbast, or kenaf core. In some embodiments, mixing at least one of thefloc and the heavy fraction with a carbon-based material comprisesmixing at least one of the floc and the heavy fraction with thecarbon-based material to provide a mixture with a heat value greaterthan about 1,000 kJ/kg.

In some embodiments, gasifying the mixture comprises at least one ofthermal gasification, pyrolytic gasification, plasma gasification,plasma-enhanced gasification, or molten-salt gasification. In someembodiments, gasifying the mixture comprises gasifying the mixture atfrom about 200° C. to about 10,000° C. In some embodiments, gasifyingthe mixture comprises gasifying the mixture in the presence of limitedoxygen. In some embodiments, gasifying the mixture in the presence oflimited oxygen comprises adjusting an amount of oxygen based on acomposition of the syngas. In some embodiments, gasifying the mixture inthe presence of limited oxygen comprises adjusting an amount of oxygenbased on a composition of the mixture. In some embodiments, gasifyingthe mixture to provide ash comprises gasifying the mixture to provide avitreous, non-toxic ash.

Some embodiments further comprise generating power from the syngas.

Some embodiments further comprise collecting volatile organic compoundsin at least one process step. Some embodiments further comprisegenerating power from the volatile organic compounds. Some embodimentsfurther comprise screening solids from the carbon-containing aqueouswaste. Some embodiments further comprise removing substantially allferromagnetic debris with a diameter greater than about 3 mm. Someembodiments further comprise compacting the mixture into briquettes orpellets before gasifying the mixture.

In some embodiments, contacting carbon-containing waste with acarbon-based material comprises contacting carbon-containing waste witha carbon-based material in a mixer unit. In some embodiments, contactingcarbon-containing waste with a carbon-based material to provide amixture comprises heating the mixture. In some embodiments, contactingcarbon-containing waste with a carbon-based material to provide amixture comprises contacting carbon-containing waste with at least oneof kenaf, kenaf bast, or kenaf core. In some embodiments, contactingcarbon-containing waste with a carbon-based material to provide amixture comprises contacting carbon-containing waste with a carbon-basedmaterial to provide a mixture with a heat value greater than about 1,000kJ/kg.

In some embodiments, contacting carbon-containing waste with acarbon-based material comprises contacting waste comprisingsubstantially hydrocarbons with the carbon-based material. In someembodiments, contacting waste comprising substantially hydrocarbonscomprises contacting at least one of petroleum, crude oil, or a refinedpetroleum. In some embodiments, contacting carbon-containing waste witha carbon-based material comprises contacting carbon-containing wastewith the carbon-based material at least partially on a body of water.

In some embodiments, remediating the carbon-containing aqueous waste isa continuous process.

In some embodiments, remediating the carbon-containing waste is acontinuous process.

Some embodiments provide a system for remediating an aqueous waste and acarbon-containing waste, the system comprising: a screening unitcomprising a carbon-containing aqueous waste inlet, a screened solidsoutlet, and a liquid outlet; a pH adjustment unit comprising an inletfluidly coupled to the liquid outlet of the screening unit, the pH andflocculating agent adjustment unit suitable for automatically adjustinga pH of an aqueous waste stream; an electrocoagulation unit comprisingan inlet fluidly coupled to the outlet of the pH adjustment unit and anoutlet; a storage unit comprising an inlet fluidly coupled to the outletof the electrocoagulation unit and an outlet, the storage unit suitablefor separating floc from an aqueous waste; a physical separation unitcomprising an inlet fluidly coupled to the outlet of theelectrocoagulation unit, the physical separation comprising a centrifugecapable of separating fluid into a heavy fraction and a light fraction,the physical separation unit comprising a heavy fraction outlet and alight fraction outlet; a purification unit comprising an inlet fluidlycoupled to the light fraction outlet of the physical separation unit,the purification unit comprising at least one of a vapor compressiondistillation unit or a membrane filter, the purification unit capable ofconverting at least a portion of the light fraction into water of aselected purity; a mixer unit comprising at least one inlet and amixture outlet, the at least one inlet fluidly coupled to the heavyfraction outlet of the physical separation unit, the at least one inletcoupled to a source of the carbon-containing waste, and the at least oneinlet coupled to a source of at least one of kenaf, kenaf bast, or kenafcore, the mixer unit comprising a continuous mixer including a heater,wherein the continuous mixer is a paddle mixer, a ribbon mixer, or acombination paddle-ribbon mixer; a briquetter comprising an inletcoupled to the mixture outlet of the mixer unit and a briquette outlet,the briquetter capable of compressing the output of the mixer unit intobriquettes; a gasification unit comprising an inlet coupled to thebriquette outlet of the briquetter, the gasification unit furthercomprising a syngas outlet; and a generator comprising an inlet fluidlycoupled to the syngas outlet of the gasification unit and an electricaloutlet, the generator comprising an internal combustion engine capableof running on at least syngas.

Some embodiments provide a system for remediating a carbon-containingaqueous waste, the system comprising: an electrocoagulation unitcomprising an aqueous waste inlet and an outlet; a physical separationunit comprising an inlet fluidly coupled to the outlet of theelectrocoagulation unit, the physical separation unit capable ofseparating fluid into a heavy fraction and a light fraction based on atleast one of size, weight, or density, the physical separation unitcomprising a heavy fraction outlet and a light fraction outlet; apurification unit comprising an inlet fluidly coupled to the lightfraction outlet of the physical separation unit, the purification unitcapable of converting at least a portion of the light fraction intowater of a selected purity; a mixer unit comprising a waste inlet, acarbon-based material inlet, and a mixture outlet, the waste inletfluidly coupled to the heavy fraction outlet of the physical separationunit and the carbon-based material inlet coupled to a source of acarbon-based material; and a gasification unit comprising an inletcoupled to the mixture outlet of the mixer unit, the gasification unitfurther comprising a syngas outlet.

Some embodiments provide a system for remediating carbon-containingwaste, the system comprising: a mixer unit comprising a waste inlet, acarbon-based material inlet, and a mixture outlet, the waste inletfluidly coupled to the heavy fraction outlet of the physical separationunit and the carbon-based material inlet coupled to a source of acarbon-based material; a gasification unit comprising an inlet coupledto the mixture outlet of the mixer unit, the gasification unit furthercomprising a syngas outlet; and a system generator comprising a fuelinlet fluidly coupled to the syngas outlet of the gasification unit, andan electrical power outlet electrically coupled to electrical powerinlets on at least one of the mixer unit or the gasification unit.

Some embodiments provide a system for remediating carbon-containingaqueous waste, the system comprising: an electrocoagulation unitcomprising an aqueous waste inlet and an outlet; a physical separationunit comprising an inlet fluidly coupled to the outlet of theelectrocoagulation unit, the physical separation unit capable ofseparating fluid into a heavy fraction and a light fraction based on atleast one of size, weight, or density, the physical separation unitcomprising a heavy fraction outlet and a light fraction outlet; and apurification unit comprising an inlet fluidly coupled to the lightfraction outlet of the physical separation unit, the purification unitcapable of converting at least a portion of the light fraction intowater of a selected purity.

In some embodiments, the electrocoagulation unit is equipped fordissolved air flotation.

In some embodiments, the physical separation unit comprises at least oneof a vortex separator, horizontal vortex separator, vertical vortexseparator, hydrocyclone, centrifuge, or decanter centrifuge. In someembodiments, the physical separation unit comprises a first physicalseparation subunit comprising an inlet fluidly coupled to the outlet ofthe electrocoagulation unit, a light fraction outlet, and a heavyfraction outlet, and a second physical separation subunit comprising aninlet fluidly connected to the heavy fraction outlet of the firstphysical separation subunit, a light fraction outlet, and a heavyfraction outlet. In some embodiments, the physical separation unitcomprises at least one of a liquid-liquid separator, a liquid-solidseparator, a liquid-liquid-liquid separator, or a liquid-liquid-solidseparator.

In some embodiments, the purification unit comprises at least one of afiltration unit, charcoal or activated carbon filter, sand filter,diatomaceous earth filter, membrane filter, microfiltration unit,ultrafiltration unit, nanofiltration unit, reverse osmosis (RO) system,distillation system, vapor compression distillation unit, UV irradiator,gamma irradiator, sterilizer, chlorinator, ozone generator,electrodeionizer, or ion exchanger. In some embodiments, thepurification unit comprises a charcoal or activated carbon filter and atleast one membrane filter. In some embodiments, the at least onemembrane filter comprises a reverse osmosis unit. In some embodiments,the purification unit comprises a charcoal or activated carbon filterand at least one vapor compression distillation unit.

In some embodiments, the mixer unit comprises at least one of a paddlemixer, ribbon mixture, paddle/ribbon mixer, plow mixer, screw mixer, Vmixer, or high-shear mixer. In some embodiments, the mixer unitcomprises a heating element. In some embodiments, the mixer unitcomprises at least one of an electromagnet or a permanent magnet.

In some embodiments, the gasification unit comprises at least one of athermal gasifier, a pyrolytic gasifier, a plasma-enhanced gasifier, aplasma gasifier, or a molten-salt gasifier. In some embodiments, thegasification unit is operable from about 200° C. to about 10,000° C.

Some embodiments further comprise a screening unit upstream of theelectrocoagulation unit, the screening unit comprising a waste inlet anda waste outlet, the waste outlet fluidly coupled to the aqueous wasteinlet of the electrocoagulation unit, the screening unit capable ofremoving at least a portion of at least one of sand, gravel, sediment,aggregate, particles, or solids above a selected size. Some embodimentsfurther comprise an in-line pH adjustment unit suitable for adjusting apH at least one of upstream of the electrocoagulation unit, within theelectrocoagulation unit, or downstream of the electrocoagulation unit.

Some embodiments further comprise a storage unit fluidly disposedbetween the electrocoagulation unit and the physical separation unit,the storage unit permitting floc formation from electrocoagulatedliquid. In some embodiments, the storage unit comprises a mechanicalseparation device capable of separating floc from liquid. In someembodiments, the mechanical separation device comprises at least one ofa skimmer or a drain. In some embodiments, the storage unit is equippedfor dissolved air flotation.

Some embodiments further comprise a compactor disposed between the mixerunit and the gasification unit, the compactor capable of compacting themixture generated by the mixer unit.

Some embodiments further comprise a system generator comprising a fuelinlet fluidly coupled to the syngas outlet of the gasification unit, andan electrical power outlet electrically coupled to electrical powerinlets on at least one of the electrocoagulation unit, the physicalseparation unit, the purification unit, the mixer unit, or thegasification unit. In some embodiments, the system generator comprisesat least one of a gas turbine, internal-combustion-engine-poweredgenerator, external-combustion-engine-powered generator, or a fuel cell.

Some embodiments further comprise a volatile organic compound collectionsystem.

In some embodiments, at least a portion of the system is modularized. Insome embodiments, the electrocoagulation unit, the physical separationunit, the purification unit, the mixer unit, and the gasification unitare disposed in at least one intermodal shipping container or semitrailer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically illustrates an embodiment of a carbon-containingwaste abatement system.

FIG. 2 schematically illustrates an embodiment of a aqueous wasteabatement system.

FIG. 3 schematically illustrates an embodiment of a waste abatementsystem comprising a carbon-containing waste stream abatement system incombination with an aqueous waste abatement system.

FIG. 4 schematically illustrates another embodiment of acarbon-containing waste abatement system.

FIG. 5 schematically illustrates another embodiment of an aqueous wasteabatement system.

FIG. 6 schematically illustrates another embodiment of an aqueous wasteabatement system.

FIG. 7 schematically illustrates another embodiment of an aqueous wasteabatement system.

FIG. 8 is a schematic top view of an embodiment of a modularized wasteabatement and remediation system.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

Disclosed herein are embodiments of a waste stream remediation orabatement devices, methods, and systems designed for remediating solidor aqueous waste streams containing organic contaminants, for example,hydrocarbons. Such waste streams are generated in oil and gasproduction, as well as in other industries, for example, paper and pulpmanufacturing, chemical production, pharmaceutical manufacturing,petroleum refining, plastic and polymer manufacturing, tanneries, fabricdye works, agriculture, breweries, distilleries, rendering plants,electronics manufacturing, explosives manufacturing, and military andmilitary contractor operations. Embodiments of devices, methods, andsystems are described with reference to remediatinghydrocarbon-containing waste streams, for example, from oil or gasdrilling operations. In some embodiments, the solid and/or liquid wasteis waste generated by hydrofracturing or fracking in oil or natural gasexploration or production. The disclosed devices, methods, and systemsare not is not limited thereto, however, and are suitable for treatingany suitable waste stream containing one or more organic components, aswell as one or more inorganic components, and optionally, an aqueouscomponent. In some embodiments, the devices, methods, and systemssubstantially completely remediate or abate an input waste streamcontaining an organic component by converting the input waste and/orwaste stream into one or more outputs comprising, for example, anon-hazardous reusable ash, syngas comprising hydrogen and/or carbonmonoxide, and/or water suitable for re-use or discharge without furthertreatment. Some embodiments include detailed descriptions of one or morecomponents, sub-components, methods, and/or options that are equallyapplicable to other embodiments, as would be understood by the skilledperson. Similar elements have similar reference characters.

FIG. 1 schematically illustrates an embodiment of a system 100 fortreating, remediating, or abating carbon-containing waste and/or wastecontaining organic compounds 102. In the illustrated embodiment, thesystem 100 comprises a mixer unit 110 coupled with a gasification unit130, which is coupled to a system generator 140. In an embodiment oftreating carbon-containing waste 102 using the abatement system 100illustrated in FIG. 1, carbon-containing waste 102 is optionallycombined with a carbon-based material 104 in the mixer unit 110, forminga mixture 112. The mixture 112 is fed into the gasification unit 130where the mixture 112 is converted into syngas 122 and ash 124. In theillustrated embodiment, the syngas 122 fuels the system generator 140,which powers the abatement system 100, and also generates excess powerin some embodiments. Optionally, volatile organic compounds 114outgassed from any combination of the carbon-containing waste 102, mixerunit 110, carbon-based material 104, or mixture 112 are collected, asindicated by the dotted lines in FIG. 1. In the illustrated embodiment,the volatile organic compounds 114 also fuel the generator 140. In otherembodiments, the volatile organic compounds 114 are used for anotherpurpose, for example, recycled and/or used as a raw material for highervalue products.

The carbon-containing waste 102 is any suitable carbon-containingfeedstock, for example, a hydrocarbon containing solid waste generatedby oil and natural gas well drilling known in the industry as“cuttings”, hydrocarbon containing solids resulting from oil spillclean-up, residue from waste water treatment, industrial waste,agricultural waste, another substantially solid feedstock containingorganic material, or any combination thereof. Some embodiments of thecarbon-containing waste 102 are substantially solid. Some embodiments ofthe carbon-containing waste 102 are largely solid, but include asemisolid component, tar, sludge, and/or liquid component. Someembodiments of the carbon-containing waste 102 are substantially atleast one of liquid, semisolid, or sludge. Some embodiments of thecarbon-containing waste comprise hydrocarbons, for example, crude oil,petroleum, and/or refined petroleum products, including gasoline,diesel, kerosene, jet fuel, bunker fuel, white gas, and/or fuel oil. Insome embodiments, the hydrocarbons are solid, liquid, and/or gas underambient conditions. Some embodiments of the carbon-containing waste 102comprise a low boiling or volatile component, for example, low molecularweight organic compounds, including hydrocarbons, alkanes, alkenes,alcohols, ketones, aldehydes, esters, terpenes, and the like. In someembodiments, the carbon-containing waste 102 comprises water. In someembodiments, the carbon-containing waste 102 is aqueous waste comprisingat least one of organic contaminants or inorganic contaminants, forexample, oil, hydrocarbons, salts, minerals, or the like. As discussedbelow, in some embodiments, carbon-containing aqueous waste 102,particularly more dilute carbon-containing aqueous waste, is treated orremediated using a different method, system, and/or apparatus. In someembodiments, the carbon-containing waste 102 comprises at least one ofaggregate, particulates, clays, minerals, absorbents (e.g., used forabsorbing spills), or disposable petroleum booms (e.g., comprisingkenaf). Carbon-containing waste 102 is also referred to as solid waste,non-aqueous waste, bulk waste, organic waste, and concentrated waste.

In the embodiment illustrated in FIG. 1, the carbon-containing waste 102is supplemented with a sufficient quantity of the carbon-based material104. In some embodiments, the carbon-based material 104 in combinationwith the carbon-containing waste 102 provide a mixture 112 with adesired heat value or caloric content. In some embodiments, thecarbon-based material 104 has another function, for example, to absorbliquid, to provide desired flow characteristics, and/or to adjust theaverage stoichiometry of the mixture. In other embodiments, thecarbon-containing waste 102 has the desired characteristics, forexample, a sufficient heat value, and is not combined with acarbon-based material. In those embodiments, references to the mixture112 in the following discussion are understood to refer to the waste102.

In some embodiments, the heat value of the mixture 112 is greater thanabout 1,000 kJ/kg (about 2,000 BTU/lb), greater than about 2,000 kJ/kg(about 4,000 BTU/lb), greater than about 2,500 kJ/kg (about 5,000BTU/lb), greater than about 3,000 kJ/kg (about 6,000 BTU/lb), greaterthan about 3,250 kJ/kg (about 6,500 BTU/lb), greater than about 3,500kJ/kg (7,000 BTU/lb), or within a range from about 1,000 kJ/kg (about2,000 BTU/lb) to about 10,000 kJ/kg (about 20,000 BTU/lb), includingfrom about 1,000 kJ/kg (about 2,000 BTU/lb) to about 7,500 kJ/kg (about15,000 BTU/lb), including from about 1,000 kJ/kg (about 2,000 BTU/lb) toabout 10,000 BTU, including from about 2,000 kJ/kg (about 4,000 BTU/lb)to about 7,500 kJ/kg (about 15,000 BTU/lb), including from about 2,500kJ/kg (about 5,000 BTU/lb) to about 5,000 kJ/kg (about 10,000 BTU/lb),including from about 3,000 kJ/kg (about 6,000 BTU/b) to about 4,500kJ/kg (about 9,000 BTU/lb), including from about 3,500 kJ/kg (about7,000 BTU/lb) to about 4,250 kJ/kg (about 8,500 BTU/lb), including about2,750 kJ/kg (about 5,500 BTU/lb), about 3,250 kJ/kg (about 6,500BTU/lb), about 3,500 kJ/kg (about 7,000 BTU/lb), about 3,750 kJ/kg(about 7,500 BTU/lb), about 4,000 kJ/kg (about 8,000 BTU/lb), about4,250 kJ/kg (about 8,500 BTU/lb), about 4,500 kJ/kg (about 9,000BTU/lb), and including ranges bordered by and including the foregoingvalues.

Some embodiments of the carbon-based materials 104 suitable forcombining with the carbon-containing waste 102 comprise at least onematerial capable of increasing the heat value of the solid waste stream102. Some embodiments of the carbon-based material 104 comprisecellulosic material. In some embodiments, the carbon based materialstream 104 comprises at least one of tires, jute, wood, wood waste, hay,paper, bitumen, lignite, coal, or agricultural residues including butnot limited to bagasse, corn stalks, corn cobs, wheat straw, straw,coconut shells, coconut husks, bamboo, and/or rice husks. Someembodiments of the carbon-based material comprise at least one ofmilkweed floss, peat moss, cotton, or cotton stalks. In someembodiments, the carbon-based material 104 comprises at least one ofkenaf, kenaf bast, or kenaf core. Kenaf core or bast has a heat value ofabout 3,750 kJ/kg (about 7,500 BTU/lb). Kenaf core is also readilyavailable and inexpensive. As used herein, the term “kenaf” includes anycombination of kenaf, kenaf bast, and kenaf core unless another meaningis expressly or implicitly stated. In some embodiments, the kenaf ispelletized or compressed, for example, for ease of transport and/orstorage. In some embodiments, the pelletized or compressed kenaf breaksapart in the mixer unit 110, thereby increasing the exposed surface areathereof, thus facilitating absorption of liquid and/or vapor, forexample, hydrophobic liquid or gas, organic compounds, and/orhydrocarbons, therein. In some embodiments, the pelletized or compressedkenaf is at least partially broken-up or otherwise uncompressed beforeit is added to the mixer unit 110.

The quantity of the carbon-based material 104 added to thecarbon-containing waste 102 depends on factors including one or more ofthe composition of the carbon-containing waste 102, the composition ofthe carbon-based material 104, a desired heat value of the mixture 112,and a desired consistency and/or texture of the mixture 112. Forexample, in some embodiments, the carbon-containing waste 102 is aliquid, is sticky and/or a sludge, and a sufficient amount of a suitablecarbon-containing material is added to provide a free-flowing mixture112. In some embodiments, a waste 102 with a low heat value, forexample, containing a high proportion of inorganic material, forexample, clay and/or rock, is combined with a sufficient amount of thecarbon-based material 104 to yield a mixture 112 with a desired heatvalue. Some embodiments of the weight percentage of the carbon-basedmaterial 104 in the mixture 112 ranges from about 1% to about 95%,including from about 2% to about 90%, including from about 10% to about90%, including from about 20% to about 80%, including from about 20% toabout 70%, including from about 30% to about 70%, including from about30% to about 60%, including from about 30% to about 50%, including fromabout 35% to about 55%, including about 30%, including about 35%,including about 40%, including about 45%, including about 50%, includingabout 55%, and including ranges bordered by and including the foregoingvalues. In some embodiments where an added carbon-based material 104 iskenaf, the kenaf comprises from about 20% to about 70% by weight of themixture 112, including from about 30% to about 70%, including from about40% to about 70%, including from about 35% to about 60%, including fromabout 40% to about 60%, including from about 45% to about 60%, includingfrom about 45% to about 70%, including from about 50% to about 70%,including about 30%, about 35%, about 40%, about 45%, about 50%, about55%, about 60%, about 65%, about 70%, and including ranges bordered byand including the foregoing values.

In the illustrated embodiment, the carbon-containing waste 102 iscombined or contacted with the carbon-based material 104 in the mixerunit 110, which in turn outputs the mixture 112. In some embodiments,the mixer unit 110 is a continuous mixer, accepting at least two solidinput streams, or at least one solid input stream and at least oneliquid stream. In other embodiments, the mixer unit 110 is a batchmixer. The mixer unit 110 comprises any suitable type of mixer, forexample, paddle mixers, ribbon mixtures, paddle/ribbon mixers, plowmixers, screw mixers, V mixers, high-shear mixers, and the like.Examples of suitable commercially available mixers include TENDERBLENDER™ continuous mixer (Scott Equipment, New Prague, Minn.), ARAN™continuous mixing plant (Gears Inc., Crested Butte, Colo.), andindustrial mixers sold by Astec Industries (Chattanooga, Tenn.) andFabromatic Industries (Ahmedabad, Gujarat, India).

In some embodiments, the carbon-containing waste 102 is contacted withat least a portion of the carbon-based material 104 outside of the mixerunit 110. For example, in some embodiments, kenaf is contacted with oiland/or hydrocarbon waste generated, for example, by processes including,but not limited to, oil well drilling, hydraulic fracturing ofunderground rock formations in oil or gas drilling, oil clean-up both onland and on water, and/or other processes. The porous bast fiber or corematerial of kenaf absorbs oil and other hydrocarbons. Kenaf also hasnaturally hydrophobic properties due to its surface waxes. Materialshaving surfaces covered by wax or wax-like compounds attract oil andother hydrocarbons while repelling water, and consequently, are suitedfor absorbing oil or other hydrocarbons spread over bodies of water.Additionally, kenaf is less dense than water (about 0.128 g/mL or about8 lb/ft³), and consequently, floats in water along with any spilled oiland/or other hydrocarbon. As discussed in U.S. Pat. No. 7,655,149, thedisclosure of which is incorporated herein, kenaf spreads over a surfaceof a body of water, allowing the kenaf to absorb any oil and/or otherhydrocarbons floating thereon, while absorbing very little water.Moreover, kenaf floats for a long time, thereby facilitating itsrecovery. Kenaf's affinity for oil and other hydrocarbons makes kenaf anideal sorbent for oil, other hydrocarbons, and/or other hydrophobicmaterials in other contexts as well, for example, spills on solidsurfaces such as on land, or other hard surfaces. In some embodiments,the resulting oil- and/or hydrocarbon-soaked kenaf is the mixture 112fed directly into the gasification unit 130, while in other embodiments,the oil- and/or hydrocarbon-soaked kenaf is combined with additionalcarbon-based material 104 in the mixer unit 110.

Some embodiments of the mixer unit 110 comprise a heating element, whichpermits heating the contents to a desired temperature. Mixing at a lowtemperature, for example, in a cold climate, is less efficient in someembodiments. Consequently, in some embodiments, the contents of themixer unit 110 are heated to a temperature within a range of from about5° C. to about 100° C., including from about 5° C. to about 90° C.,including from about 10° C. to about 80° C., including from about 10° C.to about 75° C., including from about 10° C. to about 50° C., includingfrom about 10° C. to about 30° C., including from about 10° C. to about25° C., including from about 15° C. to about 30° C., including fromabout 17° C. to about 22° C., including about 17° C., including about18° C., including about 19° C., including about 20° C., including about21° C., including about 22° C., including about 23° C., including about24° C., including about 25° C., and including ranges bordered by andincluding the foregoing values. In some embodiments, the heating elementalso dries the mixture 112 to a desired water content. In someembodiments, the desired water content of the mixture 112 will depend onfactors including the composition of the mixture 112 and thecharacteristics of the gasification unit 130.

In some embodiments, the heating element comprises at least one of anelectrical heating element, for example, a resistive heating element; asteam heating element; a heated-fluid heating element, for example, hotair, heated gas, hot water, hot oil, or another heat transfer fluid; ora radiant energy heating element, for example, infrared and/or microwaveradiation. In some embodiments, the heating element comprises a heatingjacket that surrounds at least a portion of the mixer unit 110. In someembodiments, one or more portions of the heating element extend into themixing unit 110, for example, as pipes, fins, or the like. Someembodiments of the heating element use waste heat generated by thesystem generator 140 and/or gasification unit 130. In some embodiments,the heating element is at least partially powered by the systemgenerator 140.

In some embodiments, at least one of the carbon-containing waste 102 orthe carbon-based material 104 is preheated before entering the mixerunit 110, using, for example, the types of heating elements discussedabove.

In some embodiments, volatile organic compounds 114 are released in themixer unit 110 during mixing. In some embodiments, the volatile organiccompounds 114 are removed from the mixer unit 110, for example, undervacuum, under reduced pressure, by purging with a stream of gas, and/orby condensation. In some embodiments, volatile organic compounds 114also outgas from at least one of the carbon-containing waste 102, thecarbon-based material 104, or the mixture 112. For example, in someembodiments, at least one of the carbon-containing waste 102, thecarbon-based material 104, or the mixture 112 are contained within abin, hopper, tank, duct, and/or pipe for at least some period of time,in storage and/or in transit, for example. In some of these embodiments,volatile organic compounds (VOCs) 114 are released into the bin, hopper,tank, duct, and/or pipe, and removed therefrom as discussed above inreference to removing volatile organic compounds 114 from the mixer unit110. In the embodiment illustrated in FIG. 1, volatile organic compounds114 from these sources are removed, as indicated by the dotted lines.

In the embodiment illustrated in FIG. 1, at least a portion of thevolatile organic compounds 114 are used as fuel to power the systemgenerator 140. In some embodiments, a portion of the volatile organiccompounds 114 is fed into the gasification unit 130, for example, toincrease the heat value of the feedstock thereof, to improve thegeneration of syngas, and/or as a fuel system enrichment. Consequently,some embodiments of the abatement system consume substantially all ofthe volatile organic compound 114 generated therefrom. In someembodiments, at least a portion of the volatile organic compounds 114 iscollected, for example, for recycling, as a feedstock for anotherprocess, or as a valuable product in its own right.

Some embodiments of the abatement system 100 are equipped with a metaldebris capture system that removes larger pieces of metal debris beforethe mixture 112 is fed into the gasification unit 130. In someembodiments, pieces of the drilling apparatus, for example, the drillhead, drill pipe, and/or the casing, break off during oil and/or gasdrilling, and the pieces are mixed with the cuttings. In someembodiments, the drill encounters metal in the ground, which is broughtto the surface with the drilling debris, for example, with cuttings.Some embodiments of the gasification unit 130 do not efficiently processlarger pieces of metal. Consequently, some embodiments of the abatementsystem 100 comprise at least one of a permanent magnet or electromagnetfor removing ferrous debris. In some embodiments, the mixer unit 110 isequipped with one or more permanent magnets and/or electromagnets thatcapture ferrous and/or magnetic debris during mixing. Some embodimentscomprise a magnetic capture system disposed between the mixer unit 110and the gasification unit 130, and/or upstream of the mixer unit 110. Insome embodiments, the magnetic capture system removes all ferromagneticdebris with a diameter greater than about 1 mm (about 0.04 in), greaterthan about 2 mm (about 0.08 in), greater than about 3 mm (about 0.125in), or greater than about 5 mm (about 0.2 in).

Embodiments of the gasification unit 130 substantially completelyconvert the mixture 112 into syngas 122 and ash 124. As used herein, theterm “syngas” refers to all of the gas phase components produced by thegasification unit 130, which typically include carbon monoxide, carbondioxide, hydrogen, and water vapor. In some embodiments, the syngas alsoincludes nitrogen. In the illustrated embodiment, the mixture 112 ispartially oxidized at a high-temperature and low-oxygen regime. In someembodiments, oxygen is added, depending on the characteristics, forexample, the oxygen content, hydrogen content, and/or averagestoichiometry, of the mixture 112; and/or a desired syngas composition.In some embodiments, a measured syngas composition is compared with adesired syngas composition, and the amount of added oxygen is adjustedaccordingly. In some embodiments, the oxygen source and syngas sensorare coupled in a feedback loop, thereby permitting the system 100 tomaintain a desired syngas composition under changing conditions, forexample, the composition of the carbon-containing waste 102, thecarbon-based material 104, and/or water content of the mixture 112.Suitable oxygen sources include, for example, bottled oxygen, air,and/or oxygen generators.

Embodiments of the gasification unit 130 generate substantially nohazardous or toxic waste or emissions. Some embodiments of thegasification unit 130 substantially completely remediate thecarbon-containing waste 102, converting the waste 102 an effluentcomprising substantially of syngas 122 and ash 124. In some embodiments,the gasification unit 130 is operated to favor syngas 122 production. Asdiscussed in greater detail below, in some embodiments, at least aportion of the syngas 122 fuels the system generator 140. In someembodiments, at least a portion of the syngas 122 is stored, forexample, bottled; used as a feedstock; and/or flared.

The gasification unit 130 is any suitable type, comprising, for example,thermal gasifiers, plasma gasifiers, plasma-enhanced gasifiers, andmolten-salt gasifiers. Commercially available examples of suitablegasification units include the PEPS® gasifier (Enersol TechnologiesInc., Springfield, Va.); AESI™ Modular Biomass Gasification Boilers(AESI, Inc., Wichita, Kans.); BIOGEN™ MODEL 350 Gasifier Unit (Biogen,Miami, Fla.); BIOMASS CHP™ gasifiers (Biomass CHP, LTD, Larne, NorthernIreland); MARTEZO™ gas generator (Martezo Renewable Energy, Poitiers,France); POWERHEARTH™ gasifier (International Innovations Inc., Barre,Vt.), and COOL PLASMA™ Gasification (adaptiveARC, Inc., Oceanside,Calif.).

Some embodiments of gasification unit 130 operate a temperature within arange of from about 700° C. to about 10,000° C., including from about700° C. to about 9,000° C., including from about 700° C. to about 8,000°C., including from about 700° C. to about 7,000° C., including fromabout 700° C. to about 6,000° C., including from about 700° C. to about5,000° C., including from about 700° C. to about 4,000° C., includingfrom about 700° C. to about 3,000° C., including from about 700° C. toabout 2000° C., including from about 700° C. to about 1500° C.,including from about 800° C. to about 2500° C., including from about800° C. to about 2000° C., including from about 900° C. to about 2500°C., including from about 900° C. to about 2000° C., including from about1000° C. to about 2500° C., including from about 1000° C. to about 2000°C., including from about 800° C. to about 1800° C., including from about800° C. to about 1400° C., including from about 900° C. to about 1800°C., including from about 900° C. to about 1700° C., including from about900° C. to about 1600° C., including from about 1000° C. to about 1800°C., including from about 1000° C. to about 1700° C., including fromabout 1000° C. to about 1600° C., including from about 1000° C. to about1500° C., including from about 1000° C. to about 1300° C., includingfrom about 1100° C. to about 1500° C., including from about 1100° C. toabout 1400° C., including from about 1100° C. to about 1300° C.,including about 1200° C., including about 1250° C., including about1300° C., including about 1350° C., including about 1400° C., includingabout 1450° C., including about 1500° C., including about 1150° C.,including about 1600° C., and including ranges bordered by and includingthe foregoing values.

Some embodiments of the gasification unit 130 operate at a lowertemperature, for example, as low as about 200° C. Consequently, someembodiments of the gasifier operate above about 200° C., above about250° C., above about 300° C., above about 350° C., above about 400° C.,above about 450° C., above about 500° C., above about 550° C., aboveabout 600° C., or above about 650° C.

Some embodiments of molten-salt gasifiers, also referred to asmolten-salt-catalyzed gasifiers, are operable to generate hydrogen andcarbon dioxide in addition to or instead of carbon monoxide and watervapor. Consequently, in some embodiments, the syngas 122 produced by thegasification unit 130 includes hydrogen and carbon dioxide, either aloneor in admixture with carbon monoxide and water vapor. In someembodiments comprising a molten-salt gasifier, one or more salts areadded to mixer unit 110 that produces the mixture 112 that is fed intothe gasifier. In some embodiments, one or more salts are added todirectly to the gasification unit 130, that is, separate from themixture 112. Cations of suitable salts include lithium, sodium, andpotassium. Anions of suitable salts include hydroxide, carbonate,nitrite, and nitrate. Some embodiments comprise a combination of salts,for example, a mixture at or near a eutectic. Some embodiments comprisea mixture of sodium carbonate and sodium hydroxide.

Embodiments of the gasification unit 130 are scalable, capable ofgasifying a varying batch sizes and/or feed rates of the mixture 112.For example, some embodiments of the gasification unit 130 arethrottleable from at least one lower output mode up to a maximumthroughput mode. Some embodiments of the gasification unit 130 have amaximum throughput of at least about 450 kG/hr (about 1000 pounds perhour), while producing a quantity of syngas sufficient to run a 500 kWgenerator.

In the illustrated embodiment, the syngas 122 fuels the system generator140, which provides at least a portion of the power for operating theabatement system 100. In some of these embodiments, the syngas 122provides substantially all of the fuel for the system generator 140,thereby obviating the need for a supplemental fuel for the generator140, for example, diesel, gasoline, kerosene, natural gas, or the like.Because syngas burns very cleanly and efficiently, some of theseembodiments generate substantially no emissions other than carbondioxide and water vapor. In some embodiments, at least a portion of thesyngas 122 is used for a different purpose. For example, in someembodiments, the syngas is a fuel, for example, for a boiler, gasturbine, and/or fuel cell. In some embodiments, the syngas is a rawmaterial, for example in the production of higher value commercialproducts such as transportation fuels, chemicals, hydrogen, and/orfertilizers.

In some embodiments, the ash 124 is substantially non-hazardous and/ornon-toxic, and consequently, is dischargeable or disposable with few orno limits under applicable law. The ash 124 typically comprises aninorganic material including, for example, salts, minerals, and/orglass, with the precise composition depending on the composition of thecarbon-containing waste 102 and carbon-based material 104. Someembodiments of the ash 124 are usable as aggregate, for example, inmanufacturing and/or construction. In some embodiments, the aggregate isused in the manufacture of cement with improved flexibility, to produceroofing shingles, as asphalt filler, and/or as a sandblasting agent. Insome embodiments, the ash 124 is a vitreous material that substantiallyresists leaching out of any constituent therefrom, thereby rendering theash 124 substantially non-hazardous and/or non-toxic. In some of theseembodiments, the ash 124 resembles volcanic ash, comprising silicaand/or alumina.

Some embodiments of the gasification unit 130 further comprise a filterunit that removes contaminants from the syngas 122, thereby preventingor reducing their discharge into the environment. Some embodimentscomprise a filter unit incorporated in the system generator 140 and/oras a freestanding unit. In particular, the discharge of certaincontaminants is strictly regulated in some countries and regions. Insome embodiments, the filter unit removes at least a fraction of anyheavy-metal contaminant, for example, mercury, from the effluentgenerated by the gasification unit 130. Some embodiments of the filterunit comprise at least one of a filter that removes particulates, asorbent that physically absorbs the contaminant, a reactant thatchemically binds the contaminant, or a catalytic converter thattransforms the contaminant into a more benign form. Some embodiments ofthe filter unit remove substantially all contaminants from the syngas122. Some embodiments of the filter unit comprise, for example, at leastone of a bag house, vortex filter, HEPA filter, or a catalytic scrubber.

The system generator 140 comprises any suitable electrical generator,for example, a gas turbine, internal-combustion-engine-poweredgenerator, external-combustion-engine-powered generator, and/or a fuelcell. Some embodiments of the system generator 140 run substantiallyonly on the syngas 122 generated by the gasification unit 130. Someembodiments of the system generator 140 run on hydrogen produced fromthe syngas 122. In some embodiments, the system generator 140 is capableof running on syngas 122 and another fuel, for example, diesel,kerosene, gasoline, hydrogen, and/or natural gas, which is useful, forexample, when the abatement system 100 is not generating sufficientsyngas 122. Some embodiments of the system generator 140 comprise afirst generator that is fueled solely by the syngas 122 and a secondgenerator that runs on another fuel. In some embodiments, the systemgenerator 140 produces at least sufficient energy to power the abatementsystem 100. In some embodiments, the system generator 140 generatesexcess electrical power that is transmitted elsewhere. Some embodimentsof the abatement system 100 also generate other utilities, for example,at least one of heat, steam, hot water, pressurized hydraulic fluid,compressed air, or vacuum. In some of these embodiments, the abatementsystem 100 is electrically coupled to a power grid, and is capable ofexporting the excess power to the grid as well as drawing powertherefrom if needed. Examples of suitable generators are available, forexample, from Caterpillar (Peoria, Ill.) or Cummins (Minneapolis Minn.).

FIG. 2 schematically illustrates an embodiment of a aqueous wasteremediation or abatement system 200, which is suitable for treatingwastewater created in drilling oil, gas, or water wells; flowback waterfrom hydraulic fracturing in oil and gas production; industrial wastes;and/or wastewater not suitable for discharge without treatment. Examplesinclude wastewater produced in hazardous waste clean-up and wastewaterfrom oil and/or petroleum clean-up, for example, wastewater from oilboom cleaning and wastewater from fuel tank cleaning. Some embodimentsof the aqueous waste 206 comprise hydrocarbon and/or organiccontaminants. Some embodiments of the aqueous waste 206 compriseinorganic compounds, for example, salts and/or minerals. Someembodiments of the aqueous waste remediation system 200 produceremediated water that is at least one of potable, usable as industrialwater, and/or dischargeable under applicable laws and regulations. Insome embodiments, the water produced by the system is used as boilerwater in an electrical generator; is suitable for use as or as acomponent of a drilling fluid for drilling water, oil, and/or naturalgas wells; and/or is suitable as a hydraulic fracturing fluid in oiland/or natural gas production.

The aqueous waste remediation system 200 comprises an electrocoagulationunit 260 fluidly coupled to an optional flocculation unit or storageunit 270, fluidly coupled to a physical separation unit 280, fluidlycoupled to a purification unit 290. As indicated by dotted lines in FIG.2, the illustrated embodiment is equipped to collect volatile organiccompounds from any combination of the aqueous waste 206, theelectrocoagulation unit 260, collected floc 262, storage unit 270,separation unit 280, and heavy fraction 284 as described above. Someembodiments of the remediation system 200 are capable of treatingaqueous waste in real time. Other embodiments are capable of treatingaqueous waste in batches. Other embodiments are capable of treatingaqueous waste in real time or in batches.

In an embodiment of a method for treating aqueous waste using theremediation system 200 illustrated in FIG. 2, aqueous waste 206 directedthrough an inlet into the electrocoagulation unit 260, which generates aflocculent or floc and a liquid phase. The contents are optionallytransferred into a temporary storage unit or coagulation unit 270 inwhich the floc continues to form and matures. The mixture is transferredinto the physical separation unit 280, which separates the mixture intoa light fraction 282 and a heavy fraction 284. The light fraction 282 istreated in the purification unit 290 to provide remediated water 296.

In some embodiments, the electrocoagulation unit 260 comprises a cell inwhich the aqueous waste 206 is disposed between a pair of sacrificialplates. A DC potential is applied to the sacrificial plates, therebyflocculating or precipitating impurities 262 and/or contaminants fromthe aqueous waste 206. In some embodiments, the floc or precipitate 262comprises heavy metals, colloidal particles, suspended solids, and/orbroken organic emulsions. Commercially suitable electrocoagulation units260 include SUR-FLO™ reactors (Kaselco, Shiner, Tex.); ELECTROPULSE™system (OilTrap, Tumwater, Wash.); electrocoagulation systems by PowellWater Systems Inc. (Centennial, Colo.); electrocoagulation systems byNatural Systems (www.n-systems.net); and electrocoagulation systems byEcoDwell International, LLC (Kingman, Ariz.).

In some embodiments, the electrocoagulation unit 260 processes theaqueous waste 206 in real time. In some embodiments, the aqueous waste206 residence time within the electrocoagulation unit 260 is within arange of from about 2 seconds to about 30 minutes, including from about2 seconds to about 25 minutes, including from about 2 seconds to about20 minutes, including from about 2 seconds to about 15 minutes,including from about 2 seconds to about 10 minutes, including from about2 seconds to about 8 minutes, including from about 2 seconds to about 6minutes, including from about 2 seconds to about 5 minutes, includingfrom about 2 seconds to about 4 minutes, including from about 2 secondsto about 3 minutes, including from about 2 seconds to about 2 minutes,including from about 2 seconds to about 1 minute, including from about 2seconds to about 30 seconds, including from about 2 seconds to about 15seconds. In some embodiments, the aqueous waste 206 residence timewithin the electrocoagulation unit 260 permits real-time processing. Insome embodiments, the aqueous waste 206 residence time within theelectrocoagulation unit 260 permits formation of floc 262 and real-timeremediation of aqueous waste 206.

In some embodiments, a pH of the aqueous waste 206 is adjusted toimprove the electrocoagulation process. In some embodiments, the pH isadjusted before the aqueous waste 206 is disposed in theelectrocoagulation unit 260, within the electrocoagulation unit 260,and/or after exiting the electrocoagulation unit 260, for example, inthe storage unit 270. In some embodiments, the pH is adjusted at severalpoints in the process, for example, where a first pH is advantageous ina first step and a second pH is advantageous in a second step. Someembodiments comprise an inline pH adjustment device for the aqueouswaste 206 entering the electrocoagulation unit 260. In some embodiments,the pH is adjusted to from about 6.5 to about 8.5.

In some embodiments, the aqueous waste 206 in the electrocoagulationunit 260 and/or storage unit 270 is mixed with a flocculating agent orcoagulant. Suitable flocculants include alum, clays, lime, and polymerflocculating agents, either alone or in combination.

Suitable polymer flocculating agents include cationic, anionic, and/ornon-ionic polymers with high, medium, and/or low molecular weights.Selection of a particular flocculating agent or agents depends on theimpurities or contaminants in the aqueous waste 206.

In some embodiments, a temperature of the electrocoagulation unit 260and/or storage unit 270 is selected that improves floc formation. Theselected temperature depends on factors including type and concentrationof contaminant; presence of other contaminants; characteristics of theelectrocoagulation unit 260, pH, and the like. In some embodiments, theelectrocoagulation unit 260 and/or storage unit 270 is sparged with agas to increase the likelihood of generating floating floc 262 and/or toaggregate suspended floc 262. The sparge gas or gases are selecteddepending on factors including cost, availability, safety, reactivitywith the floc, and the like. Suitable sparge gases include at least oneof air, nitrogen, or oxygen. In some embodiments, sparging theelectrocoagulation unit 260 removes and/or dilutes any hydrogen gasgenerated therein, improving safety.

In the storage unit 270, the electrocoagulated aqueous waste 206matures, the flocs 262 coagulating into larger aggregates. Someembodiments of the remediation system 200 do not comprise a storageunit. Some embodiments comprise a plurality of storage units 270, forexample, in which one or more parameters are independently adjustable ineach to improve flocculation. Examples of suitable adjustable parametersinclude at least one of pH, temperature, presence of flocculating agent,sparging with gas, agitation, or the like.

In some embodiments, residence time of the electrocoagulated aqueouswaste 206 in the storage unit 270 allows flocculent maturation orformation in a real-time remediation process. In some embodiments, theresidence time in the storage unit 270 is selected according tocharacteristics of a downstream physical separation unit 280 such as butnot limited to the physical separation unit 280 particulate cut-offsize, on characteristics of a downstream purification unit 290, oncharacteristics of an upstream electrocoagulation unit 260, or on otherwater waste stream abatement system 200 characteristics, or on anycombination thereof.

In some embodiments, residence time of a water waste stream within atemporary storage or coagulation unit 270 within a range of from about 1second to about 4 hours, including from about 1 second to about 3.5hours, including from about 1 second to about 3 hours, including fromabout 1 second to about 2.5 hours, including from about 1 second toabout 2 hours, including from about 1 second to about 1.5 hours,including from about 1 second to about 1 hour, including from about 1second to about 45 minutes, including from about 1 second to about 30minutes, including from about 1 second to about 20 minutes, includingfrom about 1 second to about 15 minutes, including from about 1 secondto about 10 minutes, including about 9 minutes, about 8 minutes, about 7minutes, about 6 minutes, about 5 minutes, about 4 minutes, about 3minutes, about 2 minutes, about 1 minute, about 30 seconds, about 15seconds, about 10 seconds, about 5 seconds, about 2 seconds, includingranges bordered and including the foregoing values.

In some embodiments, the floc 262 precipitates as a sediment and/orfloats to the surface of the liquid phase in the electrocoagulation unit260, in the storage unit 270, or in both. The buoyancy characteristicsof the floc 262 depends on factors including the composition of theaqueous waste 206, the characteristics of the electrocoagulation unit260, the pH, the temperature, the concentration of the impurities, thepresence or absence of a flocculant, the presence of gas bubbles, andthe like. In some embodiments, gas bubbles, for example, hydrogen andoxygen generated at the sacrificial electrodes of the electrocoagulationunit 260, mix with the floc 262 creating floating rafts. In someembodiments, the gas generated in the electrocoagulation unit 260 isremoved or vented for safety. In some embodiments, the vented gas isused to generate power, for example, as a fuel, or fuel and oxidant fora generator. Some embodiments of the electrocoagulation unit 260, thestorage unit 270, or both are equipped for dissolved air floatation, aprocess in which water saturated with air at above atmospheric pressureis added to the aqueous waste 206, thereby removing impurities from theaqueous waste 206 into floating rafts. Without being bound by anytheory, it is believed that tiny air bubbles adhere to impurities 262suspended in the aqueous waste 206, causing the impurities 262 to floatto the surface.

In some embodiments, the floc is mechanically removed and collected fromthe electrocoagulation unit 260 and/or the storage unit 270. Forexample, in some embodiments, sedimented floc 262 is drained from thebottom of the electrocoagulation unit 260 and/or the storage unit 270.Some embodiments of the electrocoagulation unit 260 and/or the storageunit 270 comprise a conical, pyramidal, and/or tapered bottom, whichfacilitates draining sedimented floc 262. In some embodiments, floatingfloc 262 is skimmed from the surface of the electrocoagulation unit 260and/or the storage unit 270. In some embodiments, the collected floc 262is remediated, for example, in an abatement or remediation systemdisclosed herein, for example, as a carbon-containing waste feedstock inthe system 100 illustrated in FIG. 1 and described above.

The electrocoagulated aqueous waste 206 is transferred from theelectrocoagulation unit 260 or storage unit 270 into the physicalseparation unit 280, which separates the aqueous waste 206 into thelight fraction 282 and the heavy fraction 284. Some embodiments of theheavy fraction 284 comprise heavier and/or more dense componentsremaining in the liquid phase, for example, at least one of unaggregatedand/or uncoagulated floc generated by the electrocoagulation unit 260,larger suspended solids, high-density components, or the like. Someembodiments of the light fraction 282 comprise lighter and/or less densecomponents in the liquid phase, for example, at least one of organiccompounds, smaller suspended solids, smaller unaggregated floc,low-density components, floc aggregates comprising gas bubble, or thelike. Some embodiments of the separation unit 280 effect a three-way oreven higher-order separation, providing more than two product fractions.

Embodiments of the physical separation unit 280 comprise any combinationof liquid-liquid separators, liquid-solid separators,liquid-liquid-liquid separators, and liquid-liquid-solid separators.Some embodiments of the physical separation unit 280 separate from theliquid phase at least a fraction of a solid component, for example,particles, and/or an immiscible liquid component according to at leastone of size, weight, or density. In some embodiments, the physicalseparation unit 280 separates from liquid phase substantially all solidcomponents with at least one of a size, weight, or density greater thana selected value. For example, in some embodiments, the light fraction282 comprises substantially no solid components with at least one asize, weight, or density greater than a selected value, and a heavyfraction 284 comprising substantially all of such solid components. Inembodiments in which the liquid phase comprises an immiscible liquidorganic component, the liquid organic component is partitioned accordingto density relative to the bulk liquid phase. Typically, the liquidorganic component is less dense than the bulk liquid phase, andconsequently, is partitioned into the light fraction 282. In someembodiments, however, at least a portion of the liquid organic componentis denser than the liquid phase, for example, comprising halogenatedorganic compounds, and is partitioned into the heavy fraction 284.

In some embodiments, the light fraction 282 is substantially water withdissolved impurities. In some embodiments, the heavy fraction 284comprises substantially all undissolved impurities and some water.Examples of undissolved impurities include solids, particles, floc,sediment, colloid particles, and organic compounds.

In some embodiments comprising an organic component less dense than thelight fraction 282, the organic component is separated therefrom and ispart of the heavy fraction 284. In some embodiments, the physicalseparation unit 280 comprises a liquid-liquid-liquid separator in whicha first liquid output comprises material less dense than water,including the organic component. A second output stream is the lightfraction. A third output stream is the heavy fraction 284. Someembodiments of the physical separation unit 280 comprise aliquid-liquid-solid separator with a first liquid output comprisesmaterial less dense than water, including an organic component. A secondliquid output comprises the light fraction 282, and a solid outputcomprises the heavy fraction 284.

In some embodiment, a light fraction 282 comprising an organic componentless dense than water is subjected to at least an additional physicalseparation stage or step, separating the light fraction 282 into asecond light fraction that is substantially free of the organiccomponent, and a fraction containing the organic component, which iscombined with the heavy fraction 284.

Examples of suitable physical separation units 280 comprise, forexample, at least one of a vortex separator, horizontal vortexseparator, vertical vortex separator, hydrocyclone, centrifuge, ordecanter centrifuge. Embodiments of the separation unit 280 comprising adecanter centrifuge are capable of process up to about 750 L/min (about200 gal/min). Examples of suitable commercially available physicalseparation units include BAROID™ centrifuges (Halliburton, Houston,Tex.); DECAOIL® centrifuges (Hiller GmbH, Vilsbiburg, Germany);FLOTTWEG™ separators (Flottweg AG, Vilsbiburg, Germany); centrifugesavailable from CINC Industries, Inc. (Carson City, Nev.); AZ VorSpin™Hydrocyclone (Compatible Components Corp., Houston, Tex.); and VORAXIAL®separators (Enviro Voraxial Technology, Inc, Fort Lauderdale, Fla.).

The heavy fraction 284 is optionally further process, as described ingreater detail below. In the illustrated embodiment, volatile organiccompounds 214 are collected from the aqueous waste 206, theelectrocoagulation unit 260, the storage unit 270, the separation unit280, and the floc or impurities 262, as indicated by the dotted lines.Some uses of the volatile organic compounds 214 are discussed above inconjunction with the system 100 illustrated in FIG. 1.

In the illustrated embodiment, the light fraction 282 is processed bythe purification unit 290 to provide remediated water 296. Someembodiments of the purification unit 290 also produce a concentrate 298in which impurities from the light fraction 282 are concentrated. Insome embodiments, the concentrate 298 combined with the heavy fraction284, or further treated as described below. In some embodiments, theselection of the type of purification unit 290 and/or purificationmethod depends on a target use of the remediated water. Embodiments ofthe remediated water 296 are non-hazardous and non-toxic underapplicable laws and regulations, and consequently are dischargeable orreusable without limitation. In some embodiments, the remediated water296 is usable as at least one of potable water, industrial water, boilerwater, agricultural water, process water, drilling fluid, drilling fluidbase component, or the like. In some embodiments, the purification unit290 also produces a concentrated waste, which is further remediated in aremediation or abatement system disclosed herein, for example, as acarbon-containing waste feedstock in the abatement system 100illustrated in FIG. 1 and described above.

Some embodiments of the purification unit 290 comprise at least one of afiltration unit, charcoal or activated carbon filter, sand filter,diatomaceous earth filter, membrane filter, microfiltration unit,ultrafiltration unit, nanofiltration unit, reverse osmosis (RO) system,distillation system, vapor compression distillation unit, UV irradiator,gamma irradiator, sterilizer, chlorinator, ozone generator,electrodeionizer, ion exchanger, or the like. Some embodiments use acombination of purification technologies to provide remediated water 296with the desired purity, for example, filtration and membranefiltration, or membrane filtration and distillation. Examples ofsuitable purification units and/or components thereof are commerciallyavailable from CNTC Inc. (Los Angeles, Calif.) (membrane filters);Siemens Water Technologies AG (Warrendale, Pa.) (membrane filtersincluding VANTAGE™ reverse osmosis systems); FOREVERPURE™ (Santa Clara,Calif.) (including membrane filters and vapor compression distillers);and Sundragon Salt Factory (Delray Beach, Fla.) (vapor compressiondistillers).

Some embodiments of the purification unit 290 comprise at least onemembrane filter. Membrane filtration technologies are classifiedaccording to the smallest particle size excluded by the membrane intomicrofiltration (about 0.1-10 μm), ultrafiltration (about 10³-10⁶ Da),nanofiltration (about 200-1000 Da), and reverse osmosis (about 100 Da).Each membrane filtration unit generates a permeate or filtrate, which isa purified product stream, and a concentrate or reject, a product streamin which impurities in the feedstock are concentrated. Depending on theend use of the remediated water, embodiments of the purification unit290 comprise one or more membrane filtration units. Some embodiments ofthe purification unit 290 comprise at least one hydrocarbon removaldevice upstream of the membrane filtration unit(s), for example, acharcoal or activated carbon filter.

Some embodiments employ permeate staging, in which the permeate of anupstream membrane filter is the feedstock of a downstream membranefilter, thereby reducing clogging in the downstream membrane filterand/or providing a cleaner permeate. For example, some embodimentscomprise a microfiltration membrane upstream of a reverse osmosismembrane.

Some embodiments of the purification unit 290 employ concentratestaging, in which the concentrate of an upstream filter is the feedstockfor a downstream filter. Embodiments comprising a cascading array ofmembrane filters in such a concentrate staging configuration convert alarge percentage of the light fraction 282 into purified permeate, whilegenerating a concentrate in which impurities are more concentrated.

Some embodiments comprise a plurality of membrane filtration units inparallel, thereby improving throughput. Some embodiments compriseanother purification device upstream of the membrane filter, forexample, at least one of a sediment filter or an activated carbonfilter, which protects the membrane filter from larger particles and/orchlorine.

Some embodiments of the purification unit 290 comprise one or more vaporcompression distillation units. Some embodiments of vapor compressiondistillation units produce about 60% purified distillate and about 40%residue or waste comprising concentrated impurities, for example, wherethe total dissolved solids (TDS) in the feedstock is about 130,000 mg/L.In some embodiments, the residue is itself subjected to a sequentialvapor compression distillation, thereby increasing the total percentageof distillate to up to about 84%. Depending on the concentration ofimpurities in the feedstock, for example, the light fraction 282, theyield of the purified distillate is higher in some embodiments. Forexample, in some embodiments in which the feedstock has a lower totaldissolved solids (TDS), the yield of purified distillate is higher, forexample, greater than about 60%, greater than about 70%, or greater thanabout 80%. Some embodiments comprise additional serial or sequentialpurifications of the residue or waste. In some embodiments, thepurification unit 290 comprises at least one hydrocarbon removal deviceupstream of the vapor compression distillation unit, for example, acharcoal or activated carbon filter.

FIG. 3 schematically illustrates an embodiment of an integrated wasteabatement, remediation, or treatment system 300 suitable for remediatingor abating both aqueous waste 306 and carbon-containing waste 302. Forexample, in some embodiments, a waste stream comprises both an aqueouscomponent and a non-aqueous component, for example, solids, sludge,organics, and/or foam. In some embodiments, the aqueous and non-aqueouscomponents are separated, for example, by at least one of settling,skimming, decanting, or filtering to provide the aqueous waste 306 andthe carbon-containing waste 302. In some embodiments, independentstreams of carbon-containing 302 and aqueous 306 waste are generatedconcurrently. For example, in some embodiments, multiple wells aredrilled on a single pad in which, a first well is undergoing hydraulicfracturing, thereby generating aqueous waste 306, at the same time thata second well is being drilled, thereby generating cuttings, a form ofcarbon-containing waste 302.

The components and operation of the system 300 are similar to thecomponents and operation of the abatement system 100 and remediationsystem 200 illustrated in FIGS. 1 and 2, respectively, and describedabove, and similar components and procedures are not described againhere. Briefly, aqueous waste 306 is treated in an electrocoagulationunit 360, then enters a storage unit 370. Floc/impurities 362 iscollected from either or both of the electrocoagulation unit 360 or thestorage unit 370. The treated waste 306 is separated into a lightfraction 382 and a heavy fraction 384. A purifiction unit 390 convertsthe light fraction 382 is converted into remediated water 396.Carbon-containing waste 302, collected floc 362, and the heavy fraction384 are mixed with a carbon-based material 304 in a mixer unit 310 toprovide a mixture 312, which is fed into a gasification unit 330 toprovide ash 324 and syngas 322. The syngas 322 fuels a system generator340. Optionally, volatile organic compounds 314 collected from at leastone of the aqueous waste 306, electrocoagulation unit 360, storage unit370, collected floc 362, heavy fraction 384, or carbon-containing waste302 also fuel the system generator 340. In other embodiments, the system300 comprises another combination of embodiments of a carbon-containingwaste abatement system and/or an aqueous waste remediation systemdisclose herein.

A notable feature of the system 300 is that the heavy fraction 384 fromthe separation unit 380 is fed into the mixer unit 310 where it iscombined with at least one of the carbon-based material 304 or thecarbon-containing waste 302. The heavy fraction 384 is thereby renderednon-hazardous and non-toxic as described above. In some embodiments, oneor both of floc 362 collected from the electrocoagulation unit 360and/or storage unit 370, and residue, concentrate, sediment,precipitate, or other by-product 398 from the purification unit 390 isalso fed into the mixer unit 310 and made non-hazardous and non-toxic.

In some embodiments, at least a portion of the remediated water 396 isused as boiler water in the system generator 340. In some embodiments,at least a portion of the remediated water 396 is used as a heattransfer fluid, for example, for a heating element in the mixer unit310, for cooling the system generator 340, for cooling the gasificationunit 330, and/or for cooling a distillation system in the purificationunit 360.

In the illustrated embodiment, volatile organic compounds 314 arecollected from the components of the system 300, as indicated by thedotted lines in FIG. 3, and used as fuel in the system generator. Asdiscussed above, the volatile organic compounds 314 have another use insome embodiments.

FIG. 4 schematically illustrates another embodiment of acarbon-containing waste abatement system 400, which is generally similarto the system 100 illustrated in FIG. 1 and described above. The system400 comprises carbon-containing waste 402, carbon-based material 404,mixer unit 410, mixture 412, gasification unit 430, syngas 422, systemgenerator 440, and volatile organic compounds 414 that are substantiallysimilar to the corresponding features described above with reference tothe system 100 illustrated in FIG. 1. Consequently, only differences aredescribed in detail here. Notably, the abatement system 400 furthercomprises a waste compactor, compressor, briquetter or pelletizer 420disposed between and coupled to the mixer unit 410 and the gasificationunit 412. The waste compactor 420 compresses the mixture 412 generatedby the mixer unit 410 into briquettes, pellets, and/or another compactedand/or compressed form, which have a significantly reduced volumecompared with the mixture 412. In some embodiments, the briquettespermit using a gasification unit 430 with a smaller volume, therebyreducing the abatement system 400 footprint and increasing the abatementsystem 400 portability. Because the briquettes take up less volume thanthe same weight of the uncompressed mixture 412, some embodiments of thegasification unit 430 comprise a relatively smaller combustion chamber,thereby reducing the volume of the gasification unit 430. Someembodiments of the briquettes are also easier to feed and/or to controlfeeding into the gasification unit 430 compared with the uncompressedmixture 412, which, in some embodiments, provides a more controlledgasification. In some embodiments, the briquettes are easier to storeand transport, for example, where at least some of the gasification isperformed at a remote location. Some embodiments of the waste compactor420 comprises a dryer, which significantly reduces the moisture contentof the briquettes relative to the mixture 412. Examples of suitable,commercially available waste compactors 420 include briquettersavailable from Biomass Briquette Systems, LLC (Chico, Calif.); BiomassBriquette Machine (AGICO Group, Henan, China); briquetting pressesavailable from C. F. Nielsen A/S (Baelum, Denmark); briquettersavailable from Jay Khodiyar Machine Tools (Gujarat, India); AGNI™ BioMass Briquetting Presses (Agni Engg. & Industries, Erode, India); andWEIMA™ briquette presses (WEIMA America, Inc., Fort Mill, S.C.).

As indicated by the dotted line, in the illustrated embodiment, volatileorganic compounds 414 released in the compactor 420 are optionallycollected and used as discussed above.

FIG. 5 illustrates another embodiment of a aqueous waste remediationsystem 500 that is substantially similar to the embodiment illustratedin FIG. 2 and described above. Consequently, only the differences arediscussed in detail here. Briefly, the system 500 comprises a screeningunit 550, which separates screened solids 552 from the aqueous wastestream 506. The screened aqueous waste 506 enters an electrocoagulationunit 560 and a storage unit 570, which separate floc 562 from theaqueous waste 506. A physical separation unit 580 separates the waste506 into a light fraction 582 and a heavy fraction 584. The lightfraction 582 is treated in a purification unit 590 to provide remediatedwater 596, and in some embodiments, a concentrate 598. A notabledifference is that the remediation system 500 further comprises thescreening unit 550 disposed upstream of and fluidly coupled to theelectrocoagulation unit 560.

In some embodiments, aqueous waste 506 is fed into the screening unit550 where sand, gravel, sediment, aggregate, particles, and/or solidsabove a selected size are removed therefrom, producing screened solids552. The remainder of the aqueous waste enters the electrocoagulationunit 560. In some embodiments, the screened solids 552 comprisecontaminants, for example, hazardous solids in admixture therewith;and/or organics, for example, oil, adhered thereto, and are notdisposable under applicable law. Consequently, in the illustratedembodiment, the screened solids 552 are further remediated, for example,in an abatement or remediation system disclosed herein, for example, asa carbon-containing waste feedstock for the system 100 illustrated inFIG. 1 and described above. In some embodiments, volatile organiccompounds 514 released by the screened solids 552 are optionallycollected and used as discussed above.

Some embodiment of the screening unit 550 remove particles with adiameter larger than about 0.2 mm, about 0.3 mm, about 0.4 mm, about 0.5mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1 mm,about 1.5 mm, about 2 mm, about 3 mm, about 4 mm, or about 5 mm. In someembodiments, the screening unit 550 remove particles with a diameterlarger than about 70 mesh, about 45 mesh, about 40 mesh, about 35 mesh,about 30 mesh, about 25 mesh, about 20 mesh, about 18 mesh, about 14mesh, about 10 mesh, about 7 mesh, about 5 mesh, or about 4 mesh. Insome embodiments, the screening unit 550 comprises a plurality ofsequential screens with a screen admitting larger particles upstream ofa screen admitting smaller particles. In some embodiments, the size ofparticulates removed by the screening unit 550 is selected to reducedamage to or to increase the efficiency of the electrocoagulation unit560. Screening units are optionally added to any embodiment including anaqueous waste treatment system or subsystem disclosed herein.

The screened aqueous waste 506 is treated in the electrocoagulation unit550 and storage unit 560 from which floc 562 is separated and collected.The partially treated waste 506 is separated into a heavy fraction 584and a light fraction 582, which is converted into remediated water 596by a purification unit 590.

FIG. 6 schematically illustrates another embodiment of an aqueous wasteremediation system 600 that is generally similar to the embodimentillustrated in FIGS. 2 and 5, and described above. Consequently, onlydifferences are discussed in detail here. Briefly, a screening unit 650separates screened solids 652 from an aqueous waste stream 606. Thescreened aqueous waste 606 is treated in an electrocoagulation unit 660and a storage unit 670, separating floc 662 from the aqueous waste 606.The illustrated embodiment of the system 600 further comprises a firstphysical separation unit 680 a corresponding to the physical separationunit 280 of the system of system 200; a second physical separation unit680 b fluidly coupled to the first separation unit 680 a; a firstpurification unit 690 a fluidly coupled to the first separation unit 680a, which corresponds to the purification unit 290 of system 200; and asecond purification unit 690 b fluidly coupled to the second separationunit 680 b. In the illustrated embodiment, the treated aqueous wastestream 606 enters the first separation unit 680 a, which outputs a firstlight fraction 682 a and a first heavy fraction 684 a. The first lightfraction 682 a is treated by the first purification unit 690 a, asdiscussed above, generating remediated water 696 a, and in someembodiments, a concentrate 698 a. In the illustrated embodiment, thefirst heavy fraction 684 a is a feedstock for the second physicalseparation unit 680 b, which is generally similar to the physicalseparation unit 280 of system 200. The second physical separation unit680 b converts the first heavy fraction 684 a into a second lightfraction 682 b and a second heavy fraction 684 b. The second lightfraction 682 b is treated by the second purification unit 690 b, asdiscussed above, to provide remediated water 696 b, and in someembodiments, a concentrate 698 b. Other embodiments comprise only thefirst purification unit 690 a, and the second light fraction 682 b iscombined with the first light fraction 682 a and purified therein.Consequently, the illustrated embodiment improves the yield ofremediated water from a given quantity of aqueous waste compared withthe systems illustrated in FIGS. 2 and 5. In some embodiments, thesecond heavy fraction 684 b is a feedstock in any of the embodiments ofa carbon-containing waste abatement systems disclosed herein. In theillustrated embodiment, volatile organic compounds 614 are collectedfrom any combination of the aqueous waste 606, screened solids 652,electrocoagulation unit 660, storage unit 670, floc 662, first heavyfraction 684 a, and second heavy fraction 684 b. Some embodimentsfurther comprise one or more additional physical separation units fed bythe heavy fraction generated by an upstream physical separation unit.Other embodiments of remediation systems described herein are alsooptionally equipped with multiple physical separation units andpurification units.

FIG. 7 schematically illustrates another embodiment of an aqueous wasteremediation system 700, which is generally similar to the system 200illustrated in FIG. 2 and described above. Briefly, a screening unit 750separates screened solids 752 from aqueous waste 706. Floc 762 isseparated from the screened waste 706 using an electrocoagulation unit760 and storage unit 770, as discussed above. A physical separation unit780 separates the treated waste 706 into a light fraction 782 and aheavy fraction 784. A purification unit 790 produces remediated water796 from the light fraction 782, and in some embodiments, a concentrate798. Volatile organic compounds 714 are collected from any combinationof the aqueous waste 706, screened solids 752, electrocoagulation unit760, storage unit 770, floc 762, and heavy fraction 784. Consequently,only differences between the systems are discussed in detail here. Inparticular, the remediation system 700 is a particular embodiment of theremediation system 200 in which the purification unit 790 comprises amicrofiltration unit 792 in series with a reverse osmosis (RO) unit 794.

In some embodiments, the microfiltration unit 792 removes particles witha diameter larger than about 0.1 μm, about 0.2 μm, about 0.3 μm, about0.4 μm, about 0.5 μm, about 0.6 μm, about 0.7 μm, about 0.8 μm, about0.9 μm, or about 1.0 μm. In some embodiments, the particle exclusionsize or diameter is selected to improve the performance of thedownstream RO unit 794.

Some embodiments of the abatement and remediation systems disclosedherein are automated, comprising, for example, at least one controlunit. Examples of suitable control units comprise, for example, at leastone computer, microprocessor, embedded controller, application specificintegrated circuit (ASIC), and the like, as well as a machine-readablestorage medium, and machine readable instructions stored thereon. Someembodiments further comprise one or more sensors operatively coupled toone or more of the components of the abatement or remediation systems,the sensors suitable for measuring or detecting one or more of theoperating parameters discussed in greater detail below, for example,throughput, temperature, pressure, pH, conductivity, turbidity,viscosity, color, gas composition, flow rate, power output, and thelike. The control unit adjusts the operation of one or more componentsof the system according to the data collected by the one or moresensors, thereby improving at least one aspect of the operation thereof,for example, throughput, efficiency, energy output, and/or regulatorycompliance.

In some embodiments, the abatement or remediation systems disclosedherein are operable to treat waste in a continuous process. In someembodiments, the system operates in batch mode. Some embodiments of theabatement or remediation system are operable either continuously or inbatch mode as desired. For example, in some embodiments, a batch processis more appropriate where the waste is produced intermittently and/or insmall amounts.

Some embodiments of the abatement or remediation systems disclosedherein comprise a plurality of at least one of the components. Forexample, in the embodiment illustrated in FIG. 1, some embodimentscomprise a plurality of at least one of the mixer unit 110, thegasification unit 130, or the system generator 140, which permits thesystem 100 to, for example, treat greater volumes of waste 102, treatdifferent types of waste 102, and/or continuously operation duringreconfiguration, maintenance, and/or repair.

In some embodiments, one or more of the components of the abatement orremediation systems disclosed herein, are modularized. Embodiments ofmodularized systems improve, for example, transportability, speed ofassembly, and/or configurability. For example, some embodiments of thesystems disclosed herein comprise five or fewer modules, or three orfewer modules sized as standard transportation units, discussed ingreater detail below. Some embodiments are assemblable into a workingsystem in about 24 hours or less. In some embodiments, modules areadded, removed, or replaced as the amount of waste increases, amount ofwaste decreases, or the type of waste changes.

In some embodiments, a single module comprises every component of theabatement or remediation system. In other embodiments, the abatement orremediation system comprises a plurality of modules. For example, in theembodiment illustrated in FIG. 1, at least one of the mixer unit 110,the gasification unit 130, or the system generator 140 is modularized,permitting the assembly of an abatement system 100 according to therequirements of a particular application. In some embodiments, modulesare optimized for different environmental conditions, for example,temperature and/or precipitation; type of waste; type of carbon-basedmaterial 104; volume of waste; availability of utilities, for example,electricity, and/or water; and/or regulatory requirements. In someembodiments, a module comprises one or more of the components of theabatement or remediation system mounted on a single platform or carrier.Some embodiments of the module comprises a plurality of a single type ofcomponent mounted to the single platform or carrier, as discussed above,for example, a plurality of mixer units 110, gasification units 130,and/or generators 140.

In some embodiments, the platform or carrier is a standardtransportation unit, for example, a semi trailer or an intermodalshipping container. For example, single trailers in North America aretypically about 2.6 m (about 8.5 ft) wide, and about 14.6 m (about 48ft) or about 16.2 m (about 53 ft) long. In Europe, single trailers aretypically about 16.5 m or about 18.75 m long. Other standard sizes areused in other countries and/or regions. In some embodiments, the modulesare suitable for transport in double or triple trailer configurations.Intermodal containers are typically from about 2.5 m (about 8 ft) toabout 17 m (about 56 ft) long, about 2.4 m (about 8 ft) wide, and fromabout 2.6 m (about 8.5 ft) to about 2.9 m (about 9.5 ft) high.

An example of a particular application of a modularized system is theremediation of drilling waste generated by offshore oil drilling.Portability and scalability of the modular systems permit treating thewaste on-site rather than transporting the drilling waste for off-siteremediation or disposal, thereby significantly reducing the cost.Modularizing components of the remediation or abatement system inintermodal containers facilitates transport to off-shore oil rigs,because intermodal containers are stackable, thereby saving space bothon-site and in transit, as well as loadable and off-loadable usingstandard equipment and procedures. In some embodiments, the remediatedwater and/or ash end-products of the systems and processes disclosedherein are permissibly disposed of into the ocean, thereby avoiding thecost to transport waste for on-shore processing or disposal. Embodimentsof the systems and processes also generate power, which is usable on thedrilling rig. Moreover, in some cases, the nature of the drilling wastechanges with depth of the well. Drilling fluids are typically aqueousearly in the drilling process, changing to an oil-based mud at greaterdepths. Embodiments of the modularized systems permit modifying theremediation or abatement system to accommodate the changing nature ofthe waste.

Example

FIG. 8 is a top view of an embodiment of a modularized system 800 fortreating both aqueous waste and carbon-containing waste. As such, thesystem 800 is generally similar to the system 300 illustrated in FIG. 3with elements of other embodiments, all of which are described above. Assuch, the components are generally coupled together and operated asdescribed above. The components are disposed in a first trailer 808 a, asecond trailer 808 b, and a third trailer 808 c, each of which is aNorth American standard trailer, about 16.2 m (53 ft) long by about 2.6m (8.5 ft) wide. The components within each trailer are prewired tostandardized power and data quick-interconnects. The components in eachtrailer are pre-piped to each other as required. Fluid quick connectsare supplied for fluid connections between trailers.

The first trailer 808 a houses the first half of the components of theaqueous waste remediation portion of the system 800, including apre-filter or screening unit 850, which removes particulates larger thanabout 890 μm (about 20 mesh); a pH and flocculating agent adjustmentunit 864, which is an in-line unit that automatically adjusts the pH ofthe aqueous waste stream and optionally adds a flocculating agentthereto; and an electrocoagulation unit 860. The in-line pH adjustmentunit and electrocoagulation unit are from OilTrap Environmental Products(Tumwater, Wash.) The electrical requirements of the pH and flocculatingagent adjustment unit 864 and electrocoagulation unit 860 together are240 V, 3 ph, 90 A, with a power consumption of about 43.2 KW/hr.

The second trailer 808 b houses the remainder of the aqueous wasteremediation portion of the system 800, including a storage orflocculation tank 870; a centrifuge 880, which is a Baroid decanter typecentrifuge; and a vapor compression unit 890. The centrifuge 880 isselected for reliability, throughput, and availability, with processflow rates adjustable between from about 0 and about 750 L/min (about200 gal/min). The centrifuge 880 consumes a total of about 60 hp or 45KW/hr. The vapor compression unit 890 (FOREVERPURE™, Santa Clara,Calif.) comprises a first vapor compression subunit processing theoutput of the centrifuge 880 and a second vapor compression subunitprocessing the discharge or residue from the first vapor compressionsubunit. The first subunit processes up to about 315 L/min (about 5000gal/hr) with an average power draw of about 2.6 W/L (about 10 W/gal).Each vapor compression subunit runs about 40% discharge depending on theconcentration of total dissolve solids (TDS) in the water. Assuming a130,000 (TDS) for a 20,000 L output from the centrifuge 880: Subunit 1:40% waste of 20,000 L @ 130,000 TDS=12,000 L of fresh water and a 8,000L waste stream @ 325,000 TDS, with a total power consumption of about 50KW/hr. Subunit 2: 40% waste of 8,000 L @ 325,000 TDS=4,800 L of freshwater and a 3,200 L waste stream @ 812,500 TDS, 20 KW/hr; for a total of16,800 L of clean, fresh water and discharge of 3,200 L with a 812,500TDS or 84% pure water and 16% discharge with original effluent water at130,000 TDS, with a total power consumption for both subunits of about70 KW/hr.

The second trailer 804 also houses a generator 840, which is a duel-fuelgenerator. The generator 840 comprises an internal combustion enginecapable of running on diesel fuel and syngas, as available, with aminimum output of about 500 KW/hr. The ability to run on diesel permitsoperation of the system 800 before any syngas is generated, or in thealternative, operation of only the aqueous waste remediation portion ofthe system 800, if desired. In some embodiments, when only the aqueouswaste remediation portion of the system 800 is used, third trailer isunnecessary. In some of these embodiments, by-products generated in theaqueous waste remediation portion of the system 800—for example,screened solids, collected floc, a heavy fraction from the centrifuge880, and/or a concentrate from the vapor compression unit 890—aredisposed of and/or further processed off-site. In some embodiments inwhich only aqueous waste is remediated, the third trailer 808 c is usedto remediate or abate at least some of these by-products.

The third trailer 808 c houses components of the carbon-containing wasteabatement portion of the system 800, including a mixer 810, which is aTENDER BLENDER® mixer (Scott Equipment, New Prague, Minn.) equipped witha heating element; a briquetter 820; and a gasifier 830, which is aPOWERHEARTH™ gasifier (International Innovations Inc., Barre, Vt.). Themixer 810 consumes about 15 KW/hr. The briquetter 820 consumes about 5.6KW/hr. The gasifier 830 is throttleable with a maximum throughput ofabout 7.5 Kg/min (about 1000 lb/hr) of a briquetted kenaf/waste mixture,which generates sufficient syngas to run the generator 840 at a 500 KWoutput continuously. The gasifier 830 consumes a maximum of 4 KW/hr.

The total power consumption of the system 800 is about 182.8 KW/hr,which is easily within the capacity of the generator 840. The mixer 810will consume additional power if the heating element in the mixer 810 isused. Heating, air conditioning, and lighting the trailers 808 a, 808 b,and 808 c will also draw additional power.

The above detailed description of certain embodiments is not intended tobe exhaustive or to limit the claims to the precise form disclosedabove. While specific embodiments and examples are described above forillustrative purposes, various equivalent modifications are possiblewithin the scope of the disclosure, as those skilled in the relevant artwill recognize. Each of these processes, systems, or devices isimplementable in a variety of different ways.

While certain embodiments have been described, these embodiments havebeen presented by way of example only, and are not intended to limit thescope of the disclosure. Indeed, the novel methods, devices, and systemsdescribed herein may be embodied in a variety of other forms.Furthermore, various omissions, substitutions and changes in the form ofthe methods, devices, and systems described herein may be made withoutdeparting from the spirit of the disclosure. The accompanying claims andtheir equivalents are intended to cover such forms or modifications aswould fall within the scope and spirit of the disclosure.

What is claimed is:
 1. A method for remediating a carbon-containingaqueous waste, the method comprising: electrocoagulating thecarbon-containing aqueous waste to provide floc and a liquid phase;removing the floc from the liquid phase; physically separating theliquid phase into a light fraction and a heavy fraction; converting atleast a portion of the light fraction into water with a selected purity;mixing at least one of the floc and the heavy fraction with acarbon-based material to provide a mixture; gasifying the mixture toprovide ash and syngas.
 2. The method of claim 1, wherein converting atleast a portion of the light fraction comprises at least one ofmicrofiltration, reverse osmosis, distillation, or vapor compressiondistillation.
 3. The method of claim 1, wherein mixing at least one ofthe floc and the heavy fraction with a carbon-based material to providea mixture further comprises mixing a carbon-containing waste with thecarbon-based material.
 4. The method of claim 1, wherein mixing at leastone of the floc and the heavy fraction with a carbon-based materialcomprises mixing at least one of the floc and the heavy fraction with atleast one of kenaf, kenaf bast, or kenaf core.
 5. The method of claim 1,wherein gasifying the mixture comprises at least one of thermalgasification, pyrolytic gasification, plasma gasification,plasma-enhanced gasification, or molten-salt gasification.
 6. The methodof claim 1, further comprising generating power from the syngas.
 7. Themethod of claim 1, further comprising screening solids from thecarbon-containing aqueous waste.
 8. The method of claim 1, furthercomprising compacting the mixture into briquettes or pellets beforegasifying the mixture.
 9. A system for remediating an aqueous waste anda carbon-containing waste, the system comprising: a screening unitcomprising a carbon-containing aqueous waste inlet, a screened solidsoutlet, and a liquid outlet; a pH adjustment unit comprising an inletfluidly coupled to the liquid outlet of the screening unit, the pH andflocculating agent adjustment unit suitable for automatically adjustinga pH of an aqueous waste stream; an electrocoagulation unit comprisingan inlet fluidly coupled to the outlet of the pH adjustment unit and anoutlet; a storage unit comprising an inlet fluidly coupled to the outletof the electrocoagulation unit and an outlet, the storage unit suitablefor separating floc from an aqueous waste; a physical separation unitcomprising an inlet fluidly coupled to the outlet of theelectrocoagulation unit, the physical separation comprising a centrifugecapable of separating fluid into a heavy fraction and a light fraction,the physical separation unit comprising a heavy fraction outlet and alight fraction outlet; a purification unit comprising an inlet fluidlycoupled to the light fraction outlet of the physical separation unit,the purification unit comprising at least one of a vapor compressiondistillation unit or a membrane filter, the purification unit capable ofconverting at least a portion of the light fraction into water of aselected purity; a mixer unit comprising at least one inlet and amixture outlet, the at least one inlet fluidly coupled to the heavyfraction outlet of the physical separation unit, the at least one inletcoupled to a source of the carbon-containing waste, and the at least oneinlet coupled to a source of at least one of kenaf, kenaf bast, or kenafcore, the mixer unit comprising a continuous mixer including a heater,wherein the continuous mixer is a paddle mixer, a ribbon mixer, or acombination paddle-ribbon mixer; a briquetter comprising an inletcoupled to the mixture outlet of the mixer unit and a briquette outlet,the briquetter capable of compressing the output of the mixer unit intobriquettes; a gasification unit comprising an inlet coupled to thebriquette outlet of the briquetter, the gasification unit furthercomprising a syngas outlet; and a generator comprising an inlet fluidlycoupled to the syngas outlet of the gasification unit and an electricaloutlet, the generator comprising an internal combustion engine capableof running on at least syngas.
 10. A system for remediating acarbon-containing aqueous waste, the system comprising: anelectrocoagulation unit comprising an aqueous waste inlet and an outlet;a physical separation unit comprising an inlet fluidly coupled to theoutlet of the electrocoagulation unit, the physical separation unitcapable of separating fluid into a heavy fraction and a light fractionbased on at least one of size, weight, or density, the physicalseparation unit comprising a heavy fraction outlet and a light fractionoutlet; a purification unit comprising an inlet fluidly coupled to thelight fraction outlet of the physical separation unit, the purificationunit capable of converting at least a portion of the light fraction intowater of a selected purity; a mixer unit comprising a waste inlet, acarbon-based material inlet, and a mixture outlet, the waste inletfluidly coupled to the heavy fraction outlet of the physical separationunit and the carbon-based material inlet coupled to a source of acarbon-based material; and a gasification unit comprising an inletcoupled to the mixture outlet of the mixer unit, the gasification unitfurther comprising a syngas outlet.
 11. The system of claim 10, whereinthe physical separation unit comprises at least one of a vortexseparator, horizontal vortex separator, vertical vortex separator,hydrocyclone, centrifuge, or decanter centrifuge.
 12. The system ofclaim 10, wherein the purification unit comprises a charcoal oractivated carbon filter, and at least one of at least one membranefilter or at least one vapor compression unit.
 13. The system of claim10, wherein the mixer unit comprises at least one of a paddle mixer,ribbon mixture, paddle/ribbon mixer, plow mixer, screw mixer, V mixer,or high-shear mixer.
 14. The system of claim 10, wherein the waste inletof the mixer unit is coupled to a source of a carbon-containing waste.15. The system of claim 10, wherein the gasification unit comprises atleast one of a thermal gasifier, a pyrolytic gasifier, a plasma-enhancedgasifier, a plasma gasifier, or a molten-salt gasifier.
 16. The systemof claim 10, further comprising a screening unit upstream of theelectrocoagulation unit, the screening unit comprising a waste inlet anda waste outlet, the waste outlet fluidly coupled to the aqueous wasteinlet of the electrocoagulation unit, the screening unit capable ofremoving at least a portion of at least one of sand, gravel, sediment,aggregate, particles, or solids above a selected size.
 17. The system ofclaim 10, further comprising a storage unit fluidly disposed between theelectrocoagulation unit and the physical separation unit, the storageunit permitting floc formation from electrocoagulated liquid.
 18. Thesystem of claim 10, further comprising a compactor disposed between themixer unit and the gasification unit, the compactor capable ofcompacting the mixture generated by the mixer unit.
 19. The system ofclaim 10, further comprising a system generator comprising a fuel inletfluidly coupled to the syngas outlet of the gasification unit, and anelectrical power outlet electrically coupled to electrical power inletson at least one of the electrocoagulation unit, the physical separationunit, the purification unit, the mixer unit, or the gasification unit.20. The system of claim 10, wherein the electrocoagulation unit, thephysical separation unit, the purification unit, the mixer unit, and thegasification unit are disposed in at least one intermodal shippingcontainer or semi trailer.